Form for wall panels with imbedded heating tubes

ABSTRACT

An apparatus pertaining to precast composite concrete units for use in the construction of housing and similar purposes, including the simultaneous formation of a multiplicity of units by use of a gang mold assembly and procedure, including the introduction of concrete by pumping through the bottom of a forming unit with side, end, top and bottom forming elements and containing vertically oriented light weight tubing, a steel matrix and centrally positioned insulation component, all to produce a final composite construction unit adapted for combination with other units for vertical and horizontal extension and having concrete sections surrounding a window frame, a steel matrix and a insulation member.

United States Patent [191 Fattor 1 Dec. 24, 1974 FORM FOR WALL PANELS WITH IMBEDDED HEATING TUBES 22 Filed: Nov. 17, 1972 21 Appl. No.: 307,371

[52] US. Cl 249/39, 249/79, 249/95 [51] Int. Cl. E04g 15/02 [58] Field of Search 425/242-243,

425/110, DIG. 110; 249/33-37, 79, 80, 88, 91, 94, 96-97,109,111,121,160,177, 189, 39, 95; 264/35, 333, DIG. 43

[56] References Cited UNITED STATES PATENTS 1,389,803 9/1921 Wolfe 249/33 1,465,222 8/1923 Kirton 264/35 1,570,448 1/1926 Musgrave et al. 264/35 1,863,549 6/1932 Lockwood 264/35 2,602,210 7/1952 Rumble 249/79 2,652,168 9/1953 Nelson et al.. 249/35 2,731,699 l/1956 Dubbs 264/87 2,964,821 12/1960 Meehan 425/110 2,979,801 4/1961 Gasmire 249/91 3,081,488 3/1963 Casavina et al 249/79 3,185,432 5/1965 Hagar, Jr. 249/78 3,438,161 4/1969 Koch 264/35 3,518,331 6/1970 Marin 264/35 3,693,930 9/1972 Wakefield et al 249/33 3,729,614 4/1973 Primary ExaminerRobert D. Baldwin Assistant ExaminerJohn McQuade Attorney, Agent, or FirmRichard D. Law

[5 7 ABSTRACT An apparatus pertaining to precast composite concrete units for use in the construction of housing and similar purposes, including the simultaneous formation of a multiplicity of units by use of a gang mold assembly and procedure, including the introduction of concrete by pumping through the bottom of a forming unit with side, end, top and bottom forming elements and containing vertically oriented light weight tubing, a steel matrix and centrally positioned insulation component, all to produce a final composite construction unit adapted for combination with other units for vertical and horizontal extension and having concrete sections surrounding a window frame, a steel matrix and a insulation member.

4 Claims, 6 Drawing Figures Martinet 249/78 PATENTEU UE324|974 3, 856.254

sum 2 o 5 PATENTED DEC 2 4 I974 SHEET l \Ayl/ PATENTED DEC 24 I974 sumsqgs 2 N D STORY GROUND LEVEL FORM FOR WALL PANELS WITH IMBEDDED HEATING TUBES BACKGROUND OF THE INVENTION The present invention relates to the production of precast concrete composite units, and particularly the apparatus for producing a superior unit for use in the construction industry and specifically the simultaneous production of a multiplicity of such units by the use of new and improved apparatus and manipulative steps.

In the past, the production of precast concrete composite units has been accompanied by numerous difficulties and drawbacks, including the inability to produce a multiplicity of units with uniform characteristics and features. In addition, it has been difficult to obtain a high degree of reproducibility and acceptable architectural effects in modern concrete structures. Also, a means of providing insulation of an acceptable quality has not been obtainable and the placing of such features as window and door frames in concrete walls has been most difficult and time-consuming. In the past, particularly in cold weather, concrete required much time to develop strength and in extreme cases has been known to freeze and thus be ruined. Such conditions often prohibit the pouring and forming of concrete on colder days thus producing delays and increased cost in the construction industry. Another problem has been clean separation between a forming member and the concrete wall in general and particularly at such places as window openings. Moreover, in the use of precast concrete walls, extreme difficulty has been encountered in the fabrication of a multiplicity of walls by placing one on top of the other due to the lack of suitable connecting means.

Other problems and difficulties encountered in the past include the inability to remove air pockets completely from the concrete and the introduction of window frames, electrical outlets, heating pipes, etc., within the forms prior to pouring.

Attempts to remedy the defects, difficulties and drawbacks of past techniques have been numerous. However, the success desired in apparatus, method and final product have not been achieved and the construction industry has long awaited advancements and improvements in this area.

The primary object of the present invention is to provide apparatus which overcomes the problems and deficiencies associated with past construction procedures and apparatus related to the present circumstance involving the preparation of a plurality of uniform precast composite concrete units for use in the construction industry.

Another object of my invention is to provide apparatus for the preparation of a precast composite concrete unit which includes the use of aninsulation section sandwiched between two layers of concrete, a steel matrix and supporting steel tubing within the mold around which the concrete is pumped from the bottom of the mold, and wherein a plurality of molds may be placed together in a gang mold assembly to simultaneously produce a multiplicity of concrete units.

Another object of my invention is to provide apparatus for the production of precast composite concrete units which are simple and inexpensive of construction and operation and wherein the method can be carried out at the job site even in cold weather and window and door frames can be placed prior to the introduction of the concrete into themold.

A still further object of my invention is to provide apparatus for the production of precast composite concrete units which is adaptable to and capable of use in a variety of areas in the construction industry and including, but not limited to the building of homes and apartments.

Yet another object of my invention is to provide an apparatus of the class indicated which is capable of the functions referred to and which is based upon the principles of sound construction procedure and wherein the tubing extending through the unit may be employed during the pumping of concrete as supporting members, to keep the steel matrix and insulation member from shifting. When concrete is hardened this tubing can be used as a means of connecting a multitude of walls in a vertical orientation to produce a multi-story structure. This would be done by connecting the tube extremities by means of steel dowels.

Other objects will appear hereinafter.

SUMMARY OF THE INVENTION In accordance with the present invention, it may be generally stated that it is related to new concepts in the mechanisms which would be used in the preparation of precast composite concrete units, including the use of gang mold apparatus and procedures wherein the individual molds for floor, wall, and roof slabs include forming members on the top, bottom, ends and sides with tubing, extending vertically through the mold and a steel matrix and insulation layer contained therein and wherein concrete is pumped into the mold and around the matrix tubing and insulating material with steam or other heating fluid used as a means of curing conducted through the tubing and wherein a plurality of sturdy and uniform concrete units are produced for use in the construction industry.

BRIEF DESCRIPTION OF THE DRAWINGS For amore complete understanding of my invention, reference will be made to the attached drawing figures forming a part of the present application. The drawing comprises figures wherein:

FIG. 1 is an exploded view in perspective of a typical wall section with forming accessories.

FIG. 2 is an exploded view in perspective of the general layout of the forming walls of the mold, steel matrix and auxiliary forming members.

FIG. 3 is an exploded perspective view of the window anchoring forms.

FIG. 4 is an end view of the forming walls in compression against and securing the window forms in place.

FIG. 5 is a perspective view of a gang mold assembly comprised of a plurality of molds.

FIG. 6 is a front view with a cut-a-way showing the stacking of concrete units.

DETAILED DESCRIPTION OF THE DRAWINGS Referring now to the figures and to the details of the construction and operation of my invention as best illustrated by FIGS. 1 and 2, numerals l and 2 are the vertical forming walls for the side of the mold or form. The horizontal forming plate 7 for forming the top of the unit has a vertical forming plate 5 for adjacent location in relation to the upper part of the forming wall 1 for the side of the unit. Forming member 12 extends vertically downward from the bottom of plate 7 and is designed to form the joist cavity in the unit top. Conically shaped tubular receiving members 4 extend vertically from the bottom of plate 7 and from the top of plate 11 which is the mold accessory member for forming the bottom of the concrete unit and cooperates with the other accessory members to form a closed mold. Bottom forming plate 11 contains chamber to permit the circulation of steam or other fluid through tubes 14 which are light in weight and extend vertically between plates 7 and 11 at spaced intervals corresponding to the spaced intervals of conical members 4 which the tube ends are adapted to fit together with, in a cooperative relationship. Side plate forming members extend vertically between the longitudinal ends of plates 7 and 11 and are located in adjacent relationship therewith. The side plate forming members can be moved horizontally along the length of the molding cavity to permit formation of varying lengths of slabs. Numeral 19 is a source of steam or other hot fluid. An inlet line 19a introduces fluid into chamber 15 from the heat source 19 and the fluid passing through tubes 14 is returned to the heat source 19 by means of a header 19c connected to the upper ends of the tubes 14 and to the return line 19b, as shown in Fig. l. Member 27 (FIG. 1) shows heating coil that is placed in mold cavity to provide radiant heat source for finished wall.

Both end plates (forming members 20) contain a concrete entry port adapted to receive concrete conveying conduit 26 through which concrete is transported and introduced into the mold and between the mold accessory and auxiliary elements described above. The tube elements 14 are also conduit members, as will be seen hereinafter and are inserted to additionally sustain and produce rigidity in all members to be cast as a composite concrete unit.

Inside the mold is a vertically arranged and centrally located insulative layer 17 which would preferably be about 2 inches thick or greater and designed to be sandwiched between concrete sections 8 which are formed upon the introduction of concrete through conduit 26 and entry port 25. Steel matrix 16, which may preferably be formed of heavy welded wire mesh, is located adjacent to and in the same plane as insulation layer 17 and is welded at selected locations to tubular members 14 in order to insure a correct position in the forms during the introduction of the concrete.

Alternatively, window forming members 3 may be located within the mold and are located parallel with forming walls 1 and 2 as most properly illustrated in Fig. 4 which also shows window anchoring fin 9 which extends from the window frame into the surrounding concrete. Also shown in FIG. 4 is sloped lip 10 on the window and compressive force 13 applied by walls 1 and 2 against the window form members thus preventing movement of the window member. FIG. 3 depicts the window form members in an exploded view with anchoring fin 9 and centering pins 6 which are employed to properly line up the two halves of this member. Tubular members 44 mounted in conical, tubular members 4, FIG. I, serve to line up window mold, as well as serve as means of allowing form release pressure to be applied. FIG. 3 also shows projections of conical elements 4, while 18 represents the window itself as shown in place.

With particular reference to FIG. 2, electrical box 21 with a conduit is shown as well as the particular arrangements of the accessory and auxiliary elements of the mold which combine with walls 1 and 2 to make a complete form. Numeral 23 represents a window section in the unit. Also shown in FIG. 2 are the smooth and lined interior surfaces 22 and 24 respectively of walls 1 and 2 which are used to produce a multitude of Y architectural effects on one side and a smooth surface on the other side of the unit. The smooth side is to face inward in the structure and the lined surfaces on the side of the unit will face outwardly, or on the exterior wall.

Referring now to FIG. 5, a perspective view of a gang mold assembly is depicted with a plurality of forms set up vertically and separated with a distance equal to the desired thickness of the composite concrete wall unit to be produced. Side walls 1 and 2 are shown, as is mold cavity 27. The entire assembly is held together by tension rods 29 in combination with compression elements 33 designed to produce compression forces 13. The entire arrangement is set upon base 34.

Referring now to FIG. 6, the stacking or attaching of the concrete units in a vertical orientation is illustrated. A unit with window 18 is on the ground level and a second story is completed by placing the bottom of another unit adjacent to the top of the first unit, such that respective tubular members 14 adjoin and the connection is completed by dowel connector 31.

By way of further detailed discussion and explanation of the invention, it is pointed out that the method, apparatus and product described are new concepts involving mechanisms which would be used in the construction of precast concrete homes. Generally the system employed consists of a gang molding procedure shown in FIG. 5 in which forms are set up vertically and separated by end plates 20 (FIG. 2) a distance to correspond with the length of wall section desired. By this arrangement of molding members, if 20 wall sections are needed, 21 form members would be required. Thus, in all cases, one more form member is required than the number of wall panels desired. The sections of a home that can be cast in this gang mold type of orientation are exterior bearing walls and all interior wall sections such as those of the bedrooms, bath, kitchen, etc. Roof and floor slabs can also be made by this means. A point of significance in this regard is that the outside walls and roof slabs thus formed would preferably contain 2 inches or greater of insulation sandwiched in between two sections of concrete of varying thickness. (See FIG. 1). Numeral 17 shows the insulation member. The insulation member is held in place by means of a reinforcing steel curtain 16 which is in turn secured in its location by tubular members 14 by means of welding. Finally, the tubular members 14, spaced at preferably about 24 inch centers, are held to the form cavity by connections to conically shaped tubular members 4 which are located at the upper and lower extremities of the mold cavity. The insulating core is held to the steel 15 by means of welded pins 32 which pass through the insulation layer, thus preventing this from floating upwards when the concrete is introduced.

In all this system described hereinbefore, it is believed that the functions and structure of tubular members 14 represent an important aspect of the new concept. This is so, because not only do these tubes support all members that are placed in the form, but they can be used as heating pipes while the concrete is in the forms to decrease the time of strength build-up with respect to time in general. This would be done by passing steam or hot water through the concrete matrix through the use of these tubes. Concrete could thus be poured under winter conditions without danger of freezing. In addition, these tubes could be used to intro-- duce compressed air or liquid into cavities such as window opening 18 which would force the molding members away from the concrete and cause clean separation of the form wall and the concrete wall at the time of stripping. Lastly, the tubes could be used as connection points in the circumstance involving stackin'g one wall on top of another for multiple story applications. All that would be needed to make the connection is steel dowels such as 31 in FIG. 6.

Another point of significance and importance in this forming system is that instead of pouring the concrete into the forms from the top, this system employs a method by which the concrete is pumped into the mold cavities through the bottom as shown in FIG. 2. By such a method, all parts of the mold cavity will be filled and no air pockets can exist as the air is pushed upwards ahead of the rising concrete mixture. This method of introducing the concrete will produce a unit of the greatest density which is free of typical rat-holing or air bubble entrapment.

As a further important aspect of the new concept of this invention, all door and window frames of the home would be placed into forms prior to pumping. This is made possible due to the fact that the door and window frames thus placed in the forms are held in place by the compressive force exerted by the forms themselves. Referring to FIG. 4, it can be seen that when the molds are brought together the force on the window will be sufficient to prevent movement of the unit during the pumping operation. Thus, no nails or other means of attachment to the forms is required. Members 14 would hold the window in place prior to applying compressive force. The window mold shown in FIG. 3 is split to facilitate removal after the walls 1 and 2 are removed. Also, the sloped lip is on the window mold designated as 10. This will form a slope on the outside bottom surface to facilitate runoff of rain water, etc.

The final product as seen from FIG. 1 is a composite concrete unit composed of two concrete sections 8 with insulation layer 17 sandwiched therebetween, as well as steel matrix 16 and tubular members extending therebetween and, alternatively, window 18 located therein.

The method specifically employed includes the arranging of the forming walls 1 and 2 in cooperative relationship with the auxiliary and accessory forming elements to complete a mold, including the location in said mold of insulation layer 17, steel matrix 16 and, extending therethrough, tubular members 14 which are welded to the matrix by pins 32; and, alternatively, locating between the forming walls 1 and 2, window form members 3; pumping concrete through an entry port at the bottom of the mold and forcing the concrete to fill the mold by rising and surrounding the elements therein. When necessary, steam or hot water may be circulated through tubular members 14 to prevent freezing and subsequent cracking of the product; finally, allowing the concrete to harden and stripping the mold elements away. Inthe alternative, a plurality of the molds may be combined into a gang mold assembly to simultaneously produce a plurality of composite concrete units.

Thus, the apparatus of this invention combine to produce a superior product of increased strength, durability, and utility, for use in the construction industry. Particularly, this method and apparatus avoids and overcomes the numerous problems and difficulties of the past and is of indispensable assistance in the production of precast concrete units.

The present invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The presently disclosed embodiments therefore are to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims therefore are intended to be embraced therein.

What is claimed is:

1. Apparatus for the production of precast composite concrete wall units comprised of upper and lower mold elements, side walls and members arranged to form an enclosure in the nature of a mold cavity; said upper and lower mold elements include plates; a plurality of conically shaped, tubular members positioned on said upper and lower plates and extending vertically into said mold cavity; a plurality of tubular means mounted in said mold cavity and each mounted on and fitted to an upper and lower conically shaped, tubular member for passage of steam or heated fluid therethrough; means inclusive of a source of steam or hot fluid for passing steam or heated fluid through said plurality of tubular means; a steel matrix parallel with said side walls centrally located in said mold cavity and coextensive therewith and affixed to said tubular means; and means including entry ports at the bottom of both end members for introducing fluid concrete under pressure into said mold cavity to exclude air pockets from said cavity.

2. Apparatus according to claim 1 wherein said lower mold element includes a plate and a chamber communicating with each of said tubular members and said source of steam or hot fluid.

3. Apparatus according to claim 1 wherein an insulative layer is arranged adjacent to said steel matrix whereby it is sandwiched between concrete sections when filling said mold cavity with concrete.

4. Apparatus for the production of precast composite concrete units comprised of upper and lower mold members, side wall members and end members, arranged to form an enclosure in the nature of a mold cavity for forming composite concrete slabs, there being entry ports in the bottom of both end members adapted for the introduction of concrete under pressure therethrough and into the cavity filling the same with fluid concrete from the bottom to exclude air pockets from the cavity;

said upper and lower mold members including plates having a plurality of relatively short conically shaped tubular members positioned to extend into said mold cavity and extending vertically from said plates;

a plurality of tubular members mounted in said mold cavity, each extending between an upper and a lower conically shaped tubular member and fitted thereto;

said upper and lower mold members including means for passing heating and cooling fluid through said' tubular members;

said end members being arranged to be moved horizontally along the length of the mold cavity to permit formation of varying lengths of concrete units;

a steel matrix parallel to said side wall members and centrally located in said mold cavity and welded to said tubular members;

an insulation layer member parallel and adjacent to and coextensive with said steel matrix;

a plurality of forming elements depending into said said mold cavity. 

1. Apparatus for the production of precast composite concrete wall units comprised of upper and lower mold elements, side walls and members arranged to form an enclosure in the nature of a mold cavity; said upper and lower mold elements include plates; a plurality of conically shaped, tubular members positioned on said upper and lower plates and extending vertically into said mold cavity; a plurality of tubular means mounted in said mold cavitY and each mounted on and fitted to an upper and lower conically shaped, tubular member for passage of steam or heated fluid therethrough; means inclusive of a source of steam or hot fluid for passing steam or heated fluid through said plurality of tubular means; a steel matrix parallel with said side walls centrally located in said mold cavity and coextensive therewith and affixed to said tubular means; and means including entry ports at the bottom of both end members for introducing fluid concrete under pressure into said mold cavity to exclude air pockets from said cavity.
 2. Apparatus according to claim 1 wherein said lower mold element includes a plate and a chamber communicating with each of said tubular members and said source of steam or hot fluid.
 3. Apparatus according to claim 1 wherein an insulative layer is arranged adjacent to said steel matrix whereby it is sandwiched between concrete sections when filling said mold cavity with concrete.
 4. Apparatus for the production of precast composite concrete units comprised of upper and lower mold members, side wall members and end members, arranged to form an enclosure in the nature of a mold cavity for forming composite concrete slabs, there being entry ports in the bottom of both end members adapted for the introduction of concrete under pressure therethrough and into the cavity filling the same with fluid concrete from the bottom to exclude air pockets from the cavity; said upper and lower mold members including plates having a plurality of relatively short conically shaped tubular members positioned to extend into said mold cavity and extending vertically from said plates; a plurality of tubular members mounted in said mold cavity, each extending between an upper and a lower conically shaped tubular member and fitted thereto; said upper and lower mold members including means for passing heating and cooling fluid through said tubular members; said end members being arranged to be moved horizontally along the length of the mold cavity to permit formation of varying lengths of concrete units; a steel matrix parallel to said side wall members and centrally located in said mold cavity and welded to said tubular members; an insulation layer member parallel and adjacent to and coextensive with said steel matrix; a plurality of forming elements depending into said mold cavity from the bottom of said upper plate forming joist cavities in the formed unit; window forming means fitted against said side wall members comprising split halves having centering pins for alignment of said halves, tubular members extending vertically from said window forming means arranged to line up the same with said conically shaped tubular members and said window forming means being held in position by the compressive forces on said side walls; and electrical units and connecting conduit positioned in said mold cavity. 